epaper_nametag/cable_cap.scad

// Waveshare 2.13" e-Paper HAT (B) — ESP32 Nametag Case
// Display slides in from X+; FPC cable exits freely out the open X+ side

// --- Display Dimensions (landscape: portrait rotated 90°) ---
DISP_W = 59.20;   // overall width  (X) — portrait height
DISP_D = 29.20;   // overall depth  (Y) — portrait width
DISP_T = 1.0;     // thickness      (Z)

// --- Active (Visible) Area ---
ACT_W  = 48.55;   // active area width (X) — portrait AA height
ACT_D  = 23.71;   // active area depth (Y) — portrait AA width

// Border offsets from display edge to active area:
//   X-: portrait top border  ≈ 1.95 mm  (closed/backstop side)
//   X+: portrait FPC border  ≈ 8.70 mm  (open/entry side)
//   Y±: symmetric            ≈ 2.75 mm  each side
ACT_X_OFFSET = 1.95;
ACT_Y_OFFSET = 2.75;

// --- FPC Cable (exits X+ side) ---
FPC_W   = 12.5;
FPC_T   = 0.3;
FPC_LEN = 20.0;   // visualization length of hanging tail

// --- FPC Return Pocket ---
FPC_FLOOR_DROP  = 0.75;  // extra depth below display cavity floor
FPC_POCKET_LEN  = 20.0;  // how far in from X+ face the pocket extends
FPC_POCKET_PAD  = 2.0;   // padding on each side of FPC cable width

// --- Case Parameters ---
WALL       = 3.0;   // must exceed MAG_LIP_H (2.0) to keep pocket floor
LIP        = 1.5;   // front bezel lip thickness (Z)
TOL        = 0.3;   // per-side display clearance
CHAM       = 1.0;
CHAM_ANGLE = 60;
CORNER_R   = 2.5;
CLIP_Z     = 0;     // preview: mm to remove from Z+ (0 = full model)
CLIP_Y     = 5;     // preview: mm to remove from Y+ (0 = full model)
SHOW_DISP  = true;
SCREEN_EXPLODE    = 0;     // mm to pull display toward X+ in preview

// --- Slip-Fit Cap (X+ end) ---
SHOW_CAP    = true;   // show cap in preview
CAP_ENGAGE  = 8.0;   // sleeve engagement length over case exterior (X)
CAP_WALL    = 1.5;   // sleeve and end-wall thickness
CAP_TOL     = 0.2;   // per-side slip clearance between bore and case exterior
CAP_TIP     = 0.8;   // minimum wall thickness at X- (open) edge after taper
CAP_EXPLODE = 5;     // preview: mm to pull cap away from case in X+ (0 = seated)

// --- Magnetic Strip Locating Lip (rear face) ---
MAG_L        = 1.772 * 25.4;   // strip length ≈ 45.01 mm
MAG_W        = 0.512 * 25.4;   // strip width  ≈ 13.00 mm
MAG_LIP_H    = 2.0;            // lip height protruding from rear face
MAG_LIP_WALL = 1.0;            // lip wall thickness
MAG_TOL      = 0.2;            // per-side clearance for strip fit

// --- Derived Dimensions ---
cav_w  = DISP_W + TOL * 2;
cav_d  = DISP_D + TOL * 2;
case_w = WALL + cav_w;          // no X+ wall; open for display entry
case_h = WALL + DISP_T + LIP;
case_d = WALL * 2 + cav_d;

_cham_xy = CHAM * tan(CHAM_ANGLE);

win_x = WALL + TOL + ACT_X_OFFSET;
win_y = WALL + TOL + ACT_Y_OFFSET;

// FPC return pocket geometry (X+ face)
fpc_pkt_y  = WALL + TOL + (DISP_D - FPC_W) / 2 - FPC_POCKET_PAD;
fpc_pkt_yw = FPC_W + 2 * FPC_POCKET_PAD;

// Cap derived
_cap_bore_w  = case_d + 2 * CAP_TOL;   // bore Y width
_cap_bore_h  = case_h + 2 * CAP_TOL;   // bore Z height
// FPC exit slot spans the full FPC pocket height (pocket floor → cavity ceiling)
_cap_slot_w  = FPC_W + 1.0;                                       // slot Y width
_cap_slot_h  = FPC_FLOOR_DROP + DISP_T + TOL + 2 * CAP_TOL;      // slot Z height

// Magnetic strip recess geometry (centered on back face)
_lip_il = MAG_L + 2 * MAG_TOL;
_lip_iw = MAG_W + 2 * MAG_TOL;
_lip_x  = case_w / 2 - _lip_il / 2;
_lip_y  = case_d / 2 - _lip_iw / 2;

// -------------------------------------------------------------------
// Display mockup — approximate geometry for preview only
// -------------------------------------------------------------------
module EPD213B() {
    color([0.82, 0.84, 0.80])
        cube([DISP_W, DISP_D, DISP_T]);
    color("white")
        translate([ACT_X_OFFSET, ACT_Y_OFFSET, DISP_T])
            cube([ACT_W, ACT_D, 0.02]);
    color([1.0, 0.85, 0.1])
        translate([DISP_W, (DISP_D - FPC_W) / 2, (DISP_T - FPC_T) / 2])
            cube([FPC_LEN, FPC_W, FPC_T]);
}

// -------------------------------------------------------------------

module rounded_box(l, w, h, r) {
    hull()
        for (dx = [r, l-r], dy = [r, w-r])
            translate([dx, dy, 0]) cylinder(r=r, h=h, $fn=32);
}

module epd_case() {
    difference() {
        rounded_box(case_w, case_d, case_h, CORNER_R);

        // Display cavity — extends 0.01 mm past X+ face to leave that side open
        translate([WALL, WALL, WALL])
            cube([cav_w + 0.01, cav_d, DISP_T + TOL]);

        // Active area window + chamfered top edges
        translate([win_x, win_y, WALL + DISP_T - 0.01])
            cube([ACT_W, ACT_D, LIP - CHAM + 0.02]);
        hull() {
            translate([win_x, win_y, case_h - CHAM])
                cube([ACT_W, ACT_D, 0.01]);
            translate([win_x - _cham_xy, win_y - _cham_xy, case_h])
                cube([ACT_W + 2*_cham_xy, ACT_D + 2*_cham_xy, 0.01]);
        }

        // FPC return pocket — drops floor of display cavity near X+ face
        translate([case_w - FPC_POCKET_LEN, fpc_pkt_y, WALL - FPC_FLOOR_DROP - 0.01])
            cube([FPC_POCKET_LEN + 0.02, fpc_pkt_yw, DISP_T + TOL + FPC_FLOOR_DROP + 0.01]);

        // Magnetic strip recess in back face
        translate([_lip_x, _lip_y, -0.01])
            cube([_lip_il, _lip_iw, MAG_LIP_H + 0.01]);
    }
}

// -------------------------------------------------------------------
// Slip-fit cap — slides over X+ end of case; FPC exits through end-wall slot
// -------------------------------------------------------------------
module cable_cap() {
    // Translate so case exterior Y=0, Z=0 aligns with bore inside walls
    translate([case_w - CAP_ENGAGE + CAP_EXPLODE, -CAP_TOL - CAP_WALL, -CAP_TOL - CAP_WALL])
    difference() {
        // Outer shell: hull between two square profiles
        //   X- (open end): inset to CAP_TIP wall thickness
        //   X+ (closed end): full CAP_WALL thickness
        hull() {
            translate([0, CAP_WALL - CAP_TIP, CAP_WALL - CAP_TIP])
                cube([0.01, _cap_bore_w + 2 * CAP_TIP, _cap_bore_h + 2 * CAP_TIP]);

            translate([CAP_ENGAGE + CAP_WALL - 0.01, 0, 0])
                cube([0.01, _cap_bore_w + 2 * CAP_WALL, _cap_bore_h + 2 * CAP_WALL]);
        }

        // Bore — open on X- side; closes at end wall (local x = CAP_ENGAGE)
        translate([-0.01, CAP_WALL, CAP_WALL])
            cube([CAP_ENGAGE + 0.02, _cap_bore_w, _cap_bore_h]);

        // FPC cable exit slot through end wall
        // Y: centered on case; Z: from FPC pocket floor to display cavity ceiling
        translate([CAP_ENGAGE - 0.01,
                   CAP_WALL + CAP_TOL + case_d / 2 - _cap_slot_w / 2,
                   CAP_WALL + CAP_TOL + WALL - FPC_FLOOR_DROP])
            cube([CAP_WALL + 0.02, _cap_slot_w, _cap_slot_h]);
    }
}

color("#004B49")
    intersection() {
        epd_case();
        cube([case_w + 1,
              ($preview && CLIP_Y > 0) ? max(0.01, case_d - CLIP_Y) : case_d + 1,
              ($preview && CLIP_Z > 0) ? max(0.01, case_h - CLIP_Z) : case_h + 1]);
    }

if ($preview && SHOW_DISP)
    translate([WALL + TOL + SCREEN_EXPLODE, WALL + TOL, WALL])
        EPD213B();

if (SHOW_CAP)
    color("#1A5C5B")
        intersection() {
            cable_cap();
            translate([0, -(CAP_TOL + CAP_WALL), -(CAP_TOL + CAP_WALL)])
                cube([case_w + CAP_WALL + CAP_ENGAGE + CAP_EXPLODE + 1,
                      ($preview && CLIP_Y > 0)
                          ? max(0.01, case_d + CAP_TOL + CAP_WALL - CLIP_Y)
                          : case_d + 2 * (CAP_TOL + CAP_WALL) + 1,
                      case_h + 2 * (CAP_TOL + CAP_WALL) + 1]);
        }